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Optimization of Support Structures in Additive Manufacturing (AM) Processes

Chandran, Ramya
http://rave.ohiolink.edu/etdc/view?acc_num=ucin1479819006942462

Abstract Details

2016, MS, University of Cincinnati, Engineering and Applied Science: Mechanical Engineering.
Additive Manufacturing (AM) is the process of manufacturing parts by adding successive layers of materials on top of each other. It is widely being used in industries such as automotive, medical and aerospace as objects with intricate part geometries can be manufactured with ease. AM is spread over a vast number of processes which use different fusing methods (laser sintering and melting) and different materials (metal, plastics). Many of these processes including Stereo Lithography (SLA), Electron Beam Melting, Selective Laser Melting (SLM), Digital Light Processing (DLP) require support structures for part building. Since the volume of support structures will affect the amount of post processing time, it is desirable to have minimum support structures. Post processing methods are required to remove these supports after the manufacturing of the part. In addition, support structures have impact on the finish of the part surfaces that is in contact with these supports. Hence, for improved surface quality, it is important to keep the volume of support structures and area of contact of these structures with the part at a minimum. This thesis presents a methodology for detecting and calculating the volume of support structures required to build an AM part. A point quadtree algorithm is used to calculate the support structure volume for a part at a particular orientation. The algorithm developed can handle intricate parts having internal hollow volumes that require isolated sections of support structures that may lead to larger contact surface area. Assessment of the requirement of support structure for the part is performed using a ray-triangle intersection algorithm. Furthermore, the time required to build the part is calculated based on part volume and support structure volumes. Lastly, the best build orientation is determined while minimizing the volume of support structures in conjunction with contact area of these supports.
Sam Anand, Ph.D. (Committee Chair)
Thomas Richard Huston, Ph.D. (Committee Member)
David Thompson, Ph.D. (Committee Member)
61 p.
Mechanics
Additive Manufacturing; support strucures; quadtree; Layered Manufacturing; Support contact area

Recommended Citations

Citations

  • Chandran, R. (2016). Optimization of Support Structures in Additive Manufacturing (AM) Processes [Master's thesis, University of Cincinnati]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1479819006942462

    APA Style (7th edition)

  • Chandran, Ramya. Optimization of Support Structures in Additive Manufacturing (AM) Processes. 2016. University of Cincinnati, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ucin1479819006942462.

    MLA Style (8th edition)

  • Chandran, Ramya. "Optimization of Support Structures in Additive Manufacturing (AM) Processes." Master's thesis, University of Cincinnati, 2016. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1479819006942462

    Chicago Manual of Style (17th edition)

ucin1479819006942462
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This open access ETD is published by University of Cincinnati and OhioLINK.